Mercury/Mariner Outboard 4 HP (1994 - 1997)

This Mercury/Mariner manual is 712 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specificaitons

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanicâ??s techniques

CHAPTER THREE / TROUBLESHOOTING
Safety precautions / Operating requirements / Test and repair equipment / Starting system / AC alternating current lighting coil / Battery charging system / Electrical accessories / Ignition system / Capacitor discharge ignition (2.5, 3.3, 4 and 5 hp) / Alternator driven ignition (electronic advance [20-25 hp and 20 Jet]) / Alternator drive ignition (mechanical advance [6-60 ho and 30-45 Jet]) / Capacitor discharge module (CDM) ignition (30 and 40 hp [2-cylinder]) / Capacitor discharge module (CDM) ignition (40-60 hp [serial No. 0G531301-on]) / CDM module resistance tests (optional) / Fuel system / Fuel primer and enrichment systems / Engine temperature and overheating / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrications / Fuel selection / Gasoline additives / Recommended fuel mixture ratio / Power head break-in procedure / Fuel mixing procedure / AutoBlend II injection system / Constant ratio oil injection / Variable ratio oil injection / Lower gearcase lubricant change / Jet pump maintenance / Propeller shaft service / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anticorrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Removing combustion chamber carbon / Compression test / Cylinder head bolt torque tightening / Spark plug plugs / Lower gearcase and jet pump service / Fuel filter service / Air filter service / Fuel pump / Ignition system service / Battery and starter system / On-boat performance test / Specifications

CHAPTER FIVE / SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
2.5 and 3.3 hp models / 4 and 5 hp models / 6, 8, 9.9 and 15 hp models / 20-25 hp and 20 Jet models / 30 and 40 hp (2-cylinder models) / 40 hp and 30 Jet models (4-cylinder models) / 50-60 hp and 45 Jet models (prior to serial No. 0G531301) / 40, 50 and 60 hp (serial No. 0G531301-on) / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / 2.5 and 3.3 hp carburetor / 4 and 5 hp carburetor (with integral fuel pump) / WMC series carburetor (with integral fuel pump [6-25 hp and 20 Jet]) / WMA series carburetor (40 hp [4-cylinder] and 30 Jet models) / WME series carburetor (30 and 40 hp [2- and 3-cylinder], 50-60 hp and 45 Jet) / Fuel primer solenoid (6-25 hp and 20 Jet [remote control models]) / Fuel primer valve (30-60 hp and 30 and 45 Jet [remote control models]) / Antisiphon devices / Fuel filters / Fuel tanks / Fuel hose and primer bulb / Reed valve service / Fuel bleed (recirculation) system / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Battery charging system / Fuses / Starting systems / Ignition systems / Capacitor discharge ignition (2.5, 3.3 4 and 5 hp) / Alternator driven capacitor discharge ignition (6-60 hp and 30 and 45 Jet) / Capacitor discharge module (CDM) ignition / Specifications

CHAPTER EIGHT / POWER HEAD
Power head break-in / Lubricants, sealant and adhesives / Sealing surfaces / Fasteners and torque / Removal installation / Disassembly / Cleaning and inspection / Assembly / Specifications

CHAPTER NINE / LOWER GEARCASE AND JET DRIVE UNIT
Lower gearcase / Gear case operation / Gear ratio / High-altitude operation / Service precautions / Corrosion control / Gearcase lubrication / Propeller / Trim tab adjustment / Gear housing / Water pump / Gearcase disassembly / assembly / Jet drive models / Jet pump unit maintenance / Jet pump unit service / Bearing housing / Water intake housing liner / Specifications

CHAPTER TEN / POWER TRIM AND TILT SYSTEMS AND POWER STEERING SYSTEM
Trim and tilt systems / Manual tilt systems / Power trim and tilt systems / Power trim and tilt system service / Specifications

CHAPTER ELEVEN / OIL INJECTION SYSTEM
Autoblend II injection system / Constant-ratio oil injection--40 hp and 30 Jet (4-cylinder) / Variable-ratio oil injection / Specifications

CHAPTER TWELVE / MANUAL REWIND STARTER AND REMOTE CONTROL
Manual rewind starters / Remote controls / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1994 1995 1996 1997 Mercury/Mariner 2.5 HP
1994 1995 1996 1997 Mercury/Mariner 3.3 HP
1994 1995 1996 1997 Mercury/Mariner 4 HP
1994 1995 1996 1997 Mercury/Mariner 5 HP
1994 1995 1996 1997 Mercury/Mariner 6 HP
1994 1995 1996 1997 Mercury/Mariner 8 HP
1994 1995 1996 1997 Mercury/Mariner 9.9 HP 1994 1995 1996 1997 Mercury/Mariner 15 HP
1994 1995 1996 1997 Mercury/Mariner 20 HP
1994 1995 1996 1997 Mercury/Mariner 20 Jet
1994 1995 1996 1997 Mercury/Mariner 25 HP
1994 1995 1996 1997 Mercury/Mariner 30 HP
1994 1995 1996 1997 Mercury/Mariner 30 Jet
1994 1995 1996 1997 Mercury/Mariner 40 HP
1994 1995 1996 1997 Mercury/Mariner 45 Jet
1994 1995 1996 1997 Mercury/Mariner 50 HP
1994 1995 1996 1997 Mercury/Mariner 60 HP

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Mercury/Mariner 2.5 HP (1994-1997)
Mercury/Mariner 3.3 HP (1994-1997)
Mercury/Mariner 4 HP (1994-1997)
Mercury/Mariner 5 HP (1994-1997)
Mercury/Mariner 6 HP (1994-1997)
Mercury/Mariner 8 HP (1994-1997)
Mercury/Mariner 9.9 HP (1994-1997)
Mercury/Mariner 15 HP (1994-1997)
Mercury/Mariner 20 HP (1994-1997)
Mercury/Mariner 20 Jet (1994-1997)
Mercury/Mariner 25 HP (1994-1997)
Mercury/Mariner 30 HP (1994-1997)
Mercury/Mariner 30 Jet (1994-1997)
Mercury/Mariner 40 HP (1994-1997)
Mercury/Mariner 45 Jet (1994-1997)
Mercury/Mariner 50 HP (1994-1997)
Mercury/Mariner 60 HP (1994-1997)